Crankcase ventilation self-cleaning coalescer with intermittent rotation

ABSTRACT

A method and system is provided for regenerating and cleaning an air-oil coalescer of a crankcase ventilation system of an internal combustion engine generating blowby gas in a crankcase. The coalescer coalesces oil from the blowby gas. The method and system includes regenerating and cleaning the coalescer by intermittent rotation thereof.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. patentapplication Ser. No. 12/969,742, filed Dec. 16, 2010, and acontinuation-in-part of U.S. patent application Ser. No. 12/969,755,filed Dec. 16, 2010. The 742 and '755 applications claim the benefit ofand priority from Provisional U.S. Patent Application No. 61/298,630,filed Jan. 27, 2010, Provisional U.S. Patent Application No. 61/298,635,filed Jan. 27, 2010, Provisional U.S. Patent Application No. 61/359,192,filed Jun. 28, 2010, Provisional U.S. Patent Application No. 61/383,787,filed Sep. 17, 2010, U.S. Patent Provisional Patent Application No.61/383,790, filed Sep. 17, 2010, and Provisional U.S. Patent ApplicationNo. 61/383,793, filed Sep. 17, 2010, all incorporated herein byreference.

BACKGROUND AND SUMMARY

The invention relates to internal combustion engine crankcaseventilation separators, particularly coalescers.

Internal combustion engine crankcase ventilation separators are known inthe prior art. One type of separator uses inertial impaction air-oilseparation for removing oil particles from the crankcase blowby gas oraerosol by accelerating the blowby gas stream to high velocities throughnozzles or orifices and directing same against an impactor, causing asharp directional change effecting the oil separation. Another type ofseparator uses coalescence in a coalescing filter for removing oildroplets.

The present invention arose during continuing development efforts in thelatter noted air-oil separation technology, namely removal of oil fromthe crankcase blowby gas stream by coalescence using a coalescingfilter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view of a coalescing filter assembly.

FIG. 2 is a sectional view of another coalescing filter assembly.

FIG. 3 is like FIG. 2 and shows another embodiment.

FIG. 4 is a sectional view of another coalescing filter assembly.

FIG. 5 is a schematic view illustrating operation of the assembly ofFIG. 4.

FIG. 6 is a schematic system diagram illustrating an engine intakesystem.

FIG. 7 is a schematic diagram illustrating a control option for thesystem of FIG. 6.

FIG. 8 is a flow diagram illustrating an operational control for thesystem of FIG. 6.

FIG. 9 is like FIG. 8 and shows another embodiment.

FIG. 10 is a schematic sectional view show a coalescing filter assembly.

FIG. 11 is an enlarged view of a portion of FIG. 10.

FIG. 12 is a schematic sectional view of a coalescing filter assembly.

FIG. 13 is a schematic sectional view of a coalescing filter assembly.

FIG. 14 is a schematic sectional view of a coalescing filter assembly.

FIG. 15 is a schematic sectional view of a coalescing filter assembly.

FIG. 16 is a schematic sectional view of a coalescing filter assembly.

FIG. 17 is a schematic view of a coalescing filter assembly.

FIG. 18 is a schematic sectional view of a coalescing filter assembly.

FIG. 19 is a schematic diagram illustrating a control system.

FIG. 20 is a schematic diagram illustrating a control system.

FIG. 21 is a schematic diagram illustrating a control system.

FIG. 22 is a graph showing efficiency vs. particle size.

FIG. 23 shows a control system for intermittent operation.

FIG. 24 shows one form of intermittent operation.

FIG. 25 is a graph showing restriction vs. flow.

DETAILED DESCRIPTION

FIG. 1 shows an internal combustion engine crankcase ventilationrotating coalescer 20 separating air from oil in blowby gas 22 fromengine crankcase 24. A coalescing filter assembly 26 includes an annularrotating coalescing filter element 28 having an inner periphery 30defining a hollow interior 32, and an outer periphery 34 defining anexterior 36. And inlet port 38 supplies blowby gas 22 from crankcase 24to hollow interior 32 as shown at arrows 40. An outlet port 42 deliverscleaned separated air from the noted exterior zone 36 as shown at arrows44. The direction of blowby gas flow is inside-out, namely radiallyoutwardly from hollow interior 32 to exterior 36 as shown at arrows 46.Oil in the blowby gas is forced radially outwardly from inner periphery30 by centrifugal force, to reduce clogging of the coalescing filterelement 28 otherwise caused by oil sitting on inner periphery 30. Thisalso opens more area of the coalescing filter element to flow-through,whereby to reduce restriction and pressure drop. Centrifugal forcedrives oil radially outwardly from inner periphery 30 to outer periphery34 to clear a greater volume of coalescing filter element 28 open toflow-through, to increase coalescing capacity. Separated oil drains fromouter periphery 34. Drain port 48 communicates with exterior 36 anddrains separated oil from outer periphery 34 as shown at arrow 50, whichoil may then be returned to the engine crankcase as shown at arrow 52from drain 54.

Centrifugal force pumps blowby gas from the crankcase to hollow interior32. The pumping of blowby gas from the crankcase to hollow interior 32increases with increasing speed of rotation of coalescing filter element28. The increased pumping of blowby gas 22 from crankcase 24 to hollowinterior 32 reduces restriction across coalescing filter element 28. Inone embodiment, a set of vanes may be provided in hollow interior 32 asshown in dashed line at 56, enhancing the noted pumping. The notedcentrifugal force creates a reduced pressure zone in hollow interior 32,which reduced pressure zone sucks blowby gas 22 from crankcase 24.

In one embodiment, coalescing filter element 28 is driven to rotate by amechanical coupling to a component of the engine, e.g. axially extendingshaft 58 connected to a gear or drive pulley of the engine. In anotherembodiment, coalescing filter element 28 is driven to rotate by a fluidmotor, e.g. a pelton or turbine drive wheel 60, FIG. 2, driven by pumpedpressurized oil from the engine oil pump 62 and returning same to enginecrankcase sump 64. FIG. 2 uses like reference numerals from FIG. 1 whereappropriate to facilitate understanding. Separated cleaned air issupplied through pressure responsive valve 66 to outlet 68 which is analternate outlet to that shown at 42 in FIG. 1. In another embodiment,coalescing filter element 28 is driven to rotate by an electric motor70, FIG. 3, having a drive output rotary shaft 72 coupled to shaft 58.In another embodiment, coalescing filter element 28 is driven to rotateby magnetic coupling to a component of the engine, FIGS. 4, 5. An enginedriven rotating gear 74 has a plurality of magnets such as 76 spacedaround the periphery thereof and magnetically coupling to a plurality ofmagnets 78 spaced around inner periphery 30 of the coalescing filterelement such that as gear or driving wheel 74 rotates, magnets 76 movepast, FIG. 5, and magnetically couple with magnets 78, to in turn rotatethe coalescing filter element as a driven member. In FIG. 4, separatedcleaned air flows from exterior zone 36 through channel 80 to outlet 82,which is an alternate cleaned air outlet to that shown at 42 in FIG. 1.The arrangement in FIG. 5 provides a gearing-up effect to rotate thecoalescing filter assembly at a greater rotational speed (higher angularvelocity) than driving gear or wheel 74, e.g. where it is desired toprovide a higher rotational speed of the coalescing filter element.

Pressure drop across coalescing filter element 28 decreases withincreasing rotational speed of the coalescing filter element. Oilsaturation of coalescing filter element 28 decreases with increasingrotational speed of the coalescing filter element. Oil drains from outerperiphery 34, and the amount of oil drained increases with increasingrotational speed of coalescing filter element 28. Oil particle settlingvelocity in coalescing filter element 28 acts in the same direction asthe direction of air flow through the coalescing filter element. Thenoted same direction enhances capture and coalescence of oil particlesby the coalescing filter element.

The system provides a method for separating air from oil in internalcombustion engine crankcase ventilation blowby gas by introducing a Gforce in coalescing filter element 28 to cause increased gravitationalsettling in the coalescing filter element, to improve particle captureand coalescence of submicron oil particles by the coalescing filterelement. The method includes providing an annular coalescing filterelement 28, rotating the coalescing filter element, and providinginside-out flow through the rotating coalescing filter element.

The system provides a method for reducing crankcase pressure in aninternal combustion engine crankcase generating blowby gas. The methodincludes providing a crankcase ventilation system including a coalescingfilter element 28 separating air from oil in the blowby gas, providingthe coalescing filter element as an annular element having a hollowinterior 32, supplying the blowby gas to the hollow interior, androtating the coalescing filter element to pump blowby gas out ofcrankcase 24 and into hollow interior 32 due to centrifugal forceforcing the blowby gas to flow radially outwardly as shown at arrows 46through coalescing filter element 28, which pumping effects reducedpressure in crankcase 24.

One type of internal combustion engine crankcase ventilation systemprovides open crankcase ventilation (OCV), wherein the cleaned airseparated from the blowby gas is discharged to the atmosphere. Anothertype of internal combustion crankcase ventilation system involves closedcrankcase ventilation (CCV), wherein the cleaned air separated from theblowby gas is returned to the engine, e.g. is returned to the combustionair intake system to be mixed with the incoming combustion air suppliedto the engine.

FIG. 6 shows a closed crankcase ventilation (CCV) system 100 for aninternal combustion engine 102 generating blowby gas 104 in a crankcase106. The system includes an air intake duct 108 supplying combustion airto the engine, and a return duct 110 having a first segment 112supplying the blowby gas from the crankcase to air-oil coalescer 114 toclean the blowby gas by coalescing oil therefrom and outputting cleanedair at output 116, which may be outlet 42 of FIG. 1, 68 of FIG. 2, 82 ofFIG. 4. Return duct 110 includes a second segment 118 supplying thecleaned air from coalescer 114 to air intake duct 108 to join thecombustion air being supplied to the engine. Coalescer 114 is variablycontrolled according to a given condition of the engine, to bedescribed.

Coalescer 114 has a variable efficiency variably controlled according toa given condition of the engine. In one embodiment, coalescer 114 is arotating coalescer, as above, and the speed of rotation of the coalesceris varied according to the given condition of the engine. In oneembodiment, the given condition is engine speed. In one embodiment, thecoalescer is driven to rotate by an electric motor, e.g. 70, FIG. 3. Inone embodiment, the electric motor is a variable speed electric motor tovary the speed of rotation of the coalescer. In another embodiment, thecoalescer is hydraulically driven to rotate, e.g. FIG. 2. In oneembodiment, the speed of rotation of the coalescer is hydraulicallyvaried. In this embodiment, the engine oil pump 62, FIGS. 2, 7, suppliespressurized oil through a plurality of parallel shut-off valves such as120, 122, 124 which are controlled between closed and open or partiallyopen states by the electronic control module (ECM) 126 of the engine,for flow through respective parallel orifices or nozzles 128, 130, 132to controllably increase or decrease the amount of pressurized oilsupplied against pelton or turbine wheel 60, to in turn controllablyvary the speed of rotation of shaft 58 and coalescing filter element 28.

In one embodiment, a turbocharger system 140, FIG. 6, is provided forthe internal combustion 102 generating blowby gas 104 in crankcase 106.The system includes the noted air intake duct 108 having a first segment142 supplying combustion air to a turbocharger 144, and a second segment146 supplying turbocharged combustion air from turbocharger 144 toengine 102. Return duct 110 has the noted first segment 112 supplyingthe blowby gas 104 from crankcase 106 to air-oil coalescer 114 to cleanthe blowby gas by coalescing oil therefrom and outputting cleaned air at116. The return duct has the noted second segment 118 supplying cleanedair from coalescer 114 to first segment 142 of air intake duct 108 tojoin combustion air supplied to turbocharger 144. Coalescer 114 isvariably controlled according to a given condition of at least one ofturbocharger 144 and engine 102. In one embodiment, the given conditionis a condition of the turbocharger. In a further embodiment, thecoalescer is a rotating coalescer, as above, and the speed of rotationof the coalescer is varied according to turbocharger efficiency. In afurther embodiment, the speed of rotation of the coalescer is variedaccording to turbocharger boost pressure. In a further embodiment, thespeed of rotation of the coalescer is varied according to turbochargerboost ratio, which is the ratio of pressure at the turbocharger outletversus pressure at the turbocharger inlet. In a further embodiment, thecoalescer is driven to rotate by an electric motor, e.g. 70, FIG. 3. Ina further embodiment, the electric motor is a variable speed electricmotor to vary the speed of rotation of the coalescer. In anotherembodiment, the coalescer is hydraulically driven to rotate, FIG. 2. Ina further embodiment, the speed of rotation of the coalescer ishydraulically varied, FIG. 7.

The system provides a method for improving turbocharger efficiency in aturbocharger system 140 for an internal combustion engine 102 generatingblowby gas 104 in a crankcase 106, the system having an air intake duct108 having a first segment 142 supplying combustion air to aturbocharger 144, and a second segment 146 supplying turbochargedcombustion air from the turbocharger 144 to the engine 102, and having areturn duct 110 having a first segment 112 supplying the blowby gas 104to air-oil coalescer 114 to clean the blowby gas by coalescing oiltherefrom and outputting cleaned air at 116, the return duct having asecond segment 118 supplying the cleaned air from the coalescer 114 tothe first segment 142 of the air intake duct to join combustion airsupplied to turbocharger 144. The method includes variably controllingcoalescer 114 according to a given condition of at least one ofturbocharger 144 and engine 102. One embodiment variably controlscoalescer 114 according to a given condition of turbocharger 144. Afurther embodiment provides the coalescer as a rotating coalescer, asabove, and varies the speed of rotation of the coalescer according toturbocharger efficiency. A further method varies the speed of rotationof coalescer 114 according to turbocharger boost pressure. A furtherembodiment varies the speed of rotation of coalescer 114 according toturbocharger boost ratio, which is the ratio of pressure at theturbocharger outlet versus pressure at the turbocharger inlet.

FIG. 8 shows a control scheme for CCV implementation. At step 160,turbocharger efficiency is monitored, and if the turbo efficiency is okas determined at step 162, then rotor speed of the coalescing filterelement is reduced at step 164. If the turbocharger efficiency is notok, then engine duty cycle is checked at step 166, and if the engineduty cycle is severe then rotor speed is increased at step 168, and ifengine duty cycle is not severe then no action is taken at step 170.

FIG. 9 shows a control scheme for OCV implementation. Crankcase pressureis monitored at step 172, and if it is ok as determined at step 174 thenrotor speed is reduced at step 176, and if not ok then ambienttemperature is checked at step 178 and if less than 0° C., then at step180 rotor speed is increased to a maximum to increase warm gas pumpingand increase oil-water slinging. If ambient temperature is not less than0° C., then engine idling is checked at step 182, and if the engine isidling then at step 184 rotor speed is increased and maintained, and ifthe engine is not idling, then at step 186 rotor speed is increased to amaximum for five minutes.

The flow path through the coalescing filter assembly is from upstream todownstream, e.g. in FIG. 1 from inlet port 38 to outlet port 42, e.g. inFIG. 2 from inlet port 38 to outlet port 68, e.g. in FIG. 10 from inletport 190 to outlet port 192. There is further provided in FIG. 10 incombination a rotary cone stack separator 194 located in the flow pathand separating air from oil in the blowby gas. Cone stack separators areknown in the prior art. The direction of blowby gas flow through therotating cone stack separator is inside-out, as shown at arrows 196,FIGS. 10-12. Rotating cone stack separator 194 is upstream of rotatingcoalescer filter element 198. Rotating cone stack separator 194 is inhollow interior 200 of rotating coalescer filter element 198. In FIG.12, an annular shroud 202 is provided in hollow interior 200 and islocated radially between rotating cone stack separator 194 and rotatingcoalescer filter element 198 such that shroud 202 is downstream ofrotating cone stack separator 194 and upstream of rotating coalescerfilter element 198 and such that shroud 202 provides a collection anddrain surface 204 along which separated oil drains after separation bythe rotating cone stack separator, which oil drains as shown at droplet206 through drain hole 208, which oil then joins the oil separated bycoalescer 198 as shown at 210 and drains through main drain 212.

FIG. 13 shows a further embodiment and uses like reference numerals fromabove where appropriate to facilitate understanding. Rotating cone stackseparator 214 is downstream of rotating coalescer filter element 198.The direction of flow through rotating cone stack separator 214 isinside-out. Rotating cone stack separator 214 is located radiallyoutwardly of and circumscribes rotating coalescer filter element 198.

FIG. 14 shows another embodiment and uses like reference numerals fromabove where appropriate to facilitate understanding. Rotating cone stackseparator 216 is downstream of rotating coalescer filter element 198.The direction of flow through rotating cone stack separator 216 isoutside-in, as shown at arrows 218. Rotating coalescer filter element198 and rotating cone stack separator 216 rotate about a common axis 220and are axially adjacent each other. Blowby gas flows radially outwardlythrough rotating coalescer filter element 198 as shown at arrows 222then axially as shown at arrows 224 to rotating cone stack separator 216then radially inwardly as shown at arrows 218 through rotating conestack separator 216.

FIG. 15 shows another embodiment and uses like reference numerals fromabove where appropriate to facilitate understanding. A second annularrotating coalescer filter element 230 is provided in the noted flow pathfrom inlet 190 to outlet 192 and separates air from oil in the blowbygas. The direction of flow through second rotating coalescer filterelement 230 is outside-in as shown at arrow 232. Second rotatingcoalescer filter element 230 is downstream of first rotating coalescerelement 198. First and second rotating coalescer filter elements 198 and230 rotate about a common axis 234 and are axially adjacent each other.Blowby gas flows radially outwardly as shown at arrow 222 through firstrotating coalescer filter element 198 then axially as shown at arrow 236to second rotating coalescer filter element 230 then radially inwardlyas shown at arrow 232 through second rotating coalescer filter element230.

In various embodiments, the rotating cone stack separator may beperforated with a plurality of drain holes, e.g. 238, FIG. 13, allowingdrainage therethrough of separated oil.

FIG. 16 shows another embodiment and uses like reference numerals fromabove where appropriate to facilitate understanding. An annular shroud240 is provided along the exterior 242 of rotating coalescer filterelement 198 and radially outwardly thereof and downstream thereof suchthat shroud 240 provides a collection and drain surface 244 along whichseparated oil drains as shown at droplets 246 after coalescence byrotating coalescer filter element 198. Shroud 240 is a rotating shroudand may be part of the filter frame or end cap 248. Shroud 240circumscribes rotating coalescer filter element 198 and rotates about acommon axis 250 therewith. Shroud 240 is conical and tapers along aconical taper relative to the noted axis. Shroud 240 has an innersurface at 244 radially facing rotating coalescer filter element 198 andspaced therefrom by a radial gap 252 which increases as the shroudextends axially downwardly and along the noted conical taper. Innersurface 244 may have ribs such as 254, FIG. 17, circumferentially spacedtherearound and extending axially and along the noted conical taper andfacing rotating coalescer filter element 198 and providing channeleddrain paths such as 256 therealong guiding and draining separated oilflow therealong. Inner surface 244 extends axially downwardly along thenoted conical taper from a first upper axial end 258 to a second loweraxial end 260. Second axial end 260 is radially spaced from rotatingcoalescer filter element 198 by a radial gap greater than the radialspacing of first axial end 258 from rotating coalescer filter element198. In a further embodiment, second axial end 260 has a scalloped loweredge 262, also focusing and guiding oil drainage.

FIG. 18 shows a further embodiment and uses like reference numerals fromabove where appropriate to facilitate understanding. In lieu of lowerinlet 190, FIGS. 13-15, an upper inlet port 270 is provided, and a pairof possible or alternate outlet ports are shown at 272 and 274. Oildrainage through drain 212 may be provided through a one-way check valvesuch as 276 to drain hose 278, for return to the engine crankcase, asabove.

As above noted, the coalescer can be variably controlled according to agiven condition, which may be a given condition of at least one of theengine, the turbocharger, and the coalescer. In one embodiment, thenoted given condition is a given condition of the engine, as abovenoted. In another embodiment, the given condition is a given conditionof the turbocharger, as above noted. In another embodiment, the givencondition is a given condition of the coalescer. In a version of thisembodiment, the noted given condition is pressure drop across thecoalescer. In a version of this embodiment, the coalescer is a rotatingcoalescer, as above, and is driven at higher rotational speed whenpressure drop across the coalescer is above a predetermined threshold,to prevent accumulation of oil on the coalescer, e.g. along the innerperiphery thereof in the noted hollow interior, and to lower the notedpressure drop. FIG. 19 shows a control scheme wherein the pressure drop,dP, across the rotating coalescer is sensed, and monitored by the ECM(engine control module), at step 290, and then it is determined at step292 whether dP is above a certain value at low engine RPM, and if not,then rotational speed of the coalescer is kept the same at step 294, andif dP is above a certain value then the coalescer is rotated at a higherspeed at step 296 until dP drops down to a certain point. The notedgiven condition is pressure drop across the coalescer, and the notedpredetermined threshold is a predetermined pressure drop threshold.

In a further embodiment, the coalescer is an intermittently rotatingcoalescer having two modes of operation, and is in a first stationarymode when a given condition is below a predetermined threshold, and isin a second rotating mode when the given condition is above thepredetermined threshold, with hysteresis if desired. The firststationary mode provides energy efficiency and reduction of parasiticenergy loss. The second rotating mode provides enhanced separationefficiency removing oil from the air in the blowby gas. In oneembodiment, the given condition is engine speed, and the predeterminedthreshold is a predetermined engine speed threshold. In anotherembodiment, the given condition is pressure drop across the coalescer,and the predetermined threshold is a predetermined pressure dropthreshold. In another embodiment, the given condition is turbochargerefficiency, and the predetermined threshold is a predeterminedturbocharger efficiency threshold. In a further version, the givencondition is turbocharger boost pressure, and the predeterminedthreshold is a predetermined turbocharger boost pressure threshold. In afurther version, the given condition is turbocharger boost ratio, andthe predetermined threshold is a predetermined turbocharger boost ratiothreshold, where, as above noted, turbocharger boost ratio is the ratioof pressure at the turbocharger outlet vs. pressure at the turbochargerinlet. FIG. 20 shows a control scheme for an electrical version whereinengine RPM or coalescer pressure drop is sensed at step 298 andmonitored by the ECM at step 300 and then at step 302 if the RPM orpressure is above a threshold then rotation of the coalescer isinitiated at step 304, and if the RPM or pressure is not above thethreshold then the coalescer is left in the stationary mode at step 306.FIG. 21 shows a mechanical version and uses like reference numerals fromabove where appropriate to facilitate understanding. A check valve,spring or other mechanical component at step 308 senses RPM or pressureand the decision process is carried out at steps 302, 304, 306 as above.

The noted method for improving turbocharger efficiency includes variablycontrolling the coalescer according to a given condition of at least oneof the turbocharger, the engine, and the coalescer. One embodimentvariably controls the coalescer according to a given condition of theturbocharger. In one version, the coalescer is provided as a rotatingcoalescer, and the method includes varying the speed of rotation of thecoalescer according to turbocharger efficiency, and in anotherembodiment according to turbocharger boost pressure, and in anotherembodiment according to turbocharger boost ratio, as above noted. Afurther embodiment variably controls the coalescer according to a givencondition of the engine, and in a further embodiment according to enginespeed. In a further version, the coalescer is provided as a rotatingcoalescer, and the method involves varying the speed of rotation of thecoalescer according to engine speed. A further embodiment variablycontrols the coalescer according to a given condition of the coalescer,and in a further version according to pressure drop across thecoalescer. In a further version, the coalescer is provided as a rotatingcoalescer, and the method involves varying the speed of rotation of thecoalescer according to pressure drop across the coalescer. A furtherembodiment involves intermittently rotating the coalescer to have twomodes of operation including a first stationary mode and a secondrotating mode, as above.

A method is provided for regenerating and cleaning the air-oil coalescer28, 114, 198 of a crankcase ventilation system of an internal combustionengine 102 generating blowby gas 22, 104 in a crankcase 24, 106. Thecoalescer coalesces oil from the blowby gas. The method includesregenerating and cleaning the coalescer by intermittent rotationthereof.

FIG. 22 shows fractional efficiency vs. particle size. At particle sizegreater than about 1.5μ, efficiency is roughly the same, e.g. 100%,whether the coalescer filter is rotated or not. As particle sizedecreases, efficiency drops, particularly for lower RPM (revolutions perminute).

FIG. 23 shows a control system including a pressure drop (dP) sensor orregulator 320 sensing pressure drop across the coalescer and sending asignal to the ECM 322 (engine control module) which in turn outputs asignal to a frequency generator or rotating unit 324 to rotate thecoalescer when pressure drop across the latter rises above a giventhreshold. FIG. 24 illustrates intermittent operation wherein thecoalescer is stationary at 326 and the pressure drop thereacrossincreases. When the pressure drop reaches a given threshold such as 328,the coalescer is rotated, and the pressure drop thereacross decreases asshown at 330. When the pressure drop reaches a lower threshold such as332, the rotation is stopped. The pressure drop then begins increasingagain at 334, and the cycle repeats. The coalescer is stationary duringintervals such as 326, 334, during which pressure drop thereacrossincreases. The coalescer spins during intervals such as 330, duringwhich the pressure drop thereacross decreases due to the cleaning andregenerating thereof, as the coalescer becomes unsaturated. FIG. 25shows restriction levels of the same coalescer element after a series ofstatic and rotating modes. The first bar indicates the restriction after2000 hours of operation in a static mode. Rotating the coalescer reducesthe restriction from bar 1 to bar 2, whereafter the rotation is stoppedand the restriction increases from bar 2 to bar 3, whereafter thecoalescer element is again rotated and the restriction decreases frombar 3 to bar 4. Various other intermittent operational patterns may befollowed.

Regeneration of the coalescer by intermittent rotation retains highefficiency and clean coalescing filter media and low pressure drop forthe life of the coalescer. The high efficiency is produced byefficiently draining the liquid from the filter media with intermittentrotation. Static coalescers have a finite life and must be serviced andreplaced. Rotating coalescers, on the other hand, provide higherefficiency at a lower pressure drop than static coalescers and canpotentially last the life of the engine, but require energy input tocause or drive the rotation, and may be more complex and costly from afirst fit point of view. Customers are increasingly demanding acrankcase ventilation separator system that will last the life of theengine, provide high oil mist removal efficiency with low restriction,and with minimal to no parasitic energy loss from the engine. Thecoalescer fibrous media saturates with contaminants such as soot and oilin the engine crankcase ventilation blowby gas, reducing the life of thecoalescer filter element. Fibrous polymer media traps the oil within thefiber matrix, and the build-up of trapped oil ultimately results in asaturated coalescer element condition which raises the crankcasepressure to the point where the coalescer element needs to be changed.Intermittent rotation extends coalescer filter life and reducesparasitic energy loss otherwise needed to accomplish continuousrotation.

The present method regenerates and cleans the coalescer by applyingcentrifugal force thereto by intermittent rotation thereof. In oneembodiment, the intermittent rotation is controlled according to a givenparameter. In one embodiment, the given parameter is a condition of thecoalescer. In one embodiment, the given parameter is a condition of theengine. In one embodiment, the given parameter is crankcase pressure ofthe engine. In one embodiment, the given parameter is operationalservice time of the engine. In one embodiment, the given parameter ismileage of a vehicle driven by the engine.

In one embodiment, the method includes regenerating and cleaning thecoalescer by intermittent operation driven by a rotary shaft. In oneembodiment, the rotary shaft is driven by the engine. In one embodiment,the method includes regenerating and cleaning the coalescer byintermittent rotation driven by an electric motor. In one embodiment,the method includes regenerating and cleaning the coalescer byintermittent rotation driven by a hydraulic motor. In one embodiment,the method includes regenerating and cleaning the coalescer byintermittent rotation driven by pressurized engine oil. In oneembodiment, the method includes regenerating and cleaning the coalescerby intermittent rotation driven by pressurized engine oil driving apelton turbine. In one embodiment, the engine has an oil pump pumpinglubricating oil to components of the engine, and the method includesregenerating and cleaning the coalescer by intermittent rotation drivenby pumped oil from the oil pump. In one embodiment, the oil pump has arelief valve returning excess oil to a sump to protect againstoverpressure, and the method includes regenerating and cleaning thecoalescer by intermittent rotation driven by excess oil from the reliefvalve.

In one embodiment, the method includes regenerating and cleaning thecoalescer by intermittent rotation commanded when to spin and when notto spin. In one embodiment, the method includes regenerating andcleaning the coalescer by intermittent rotation at a commanded frequencyhaving a plurality of cycles, each cycle having an off interval duringwhich the coalescer is stationary and nonrotated, and an on intervalduring which the coalescer is rotated. In one embodiment, at least oneof a) the commanded frequency, b) the duty cycle of the commandedfrequency between the off and on intervals, and c) the speed of rotationduring the on interval, is controlled according to a given parameter. Inone embodiment, during the on interval, the method includes pulsing therotation of the coalescer to provide pulsed rotation thereof, includinga plurality of centrifugal force impulses thereto during rotation duringthe on interval. In one embodiment, during the on interval, the methodincludes pulsing the rotation of the coalescer to provide a plurality ofaccelerational bursts during rotation thereof. In one embodiment, themethod includes regenerating and cleaning the coalescer by intermittentrotation while the coalescer is mounted to the engine.

In one embodiment, the noted given parameter or trigger for rotation isexcess oil flow from the noted relief valve of the oil pump. In thisembodiment, rotation of the coalescer takes place only when the systemoil pressure reaches a higher or excess level above that needed tolubricate engine components, and thus the coalescer rotational systemwould not “steal” oil from the lube system otherwise needed at lowerengine RPMs or system pressures. In another embodiment, the parameter ortrigger for coalescer rotation is crankcase pressure. In one embodiment,the coalescer element is integrated with a pressure sensor on a rotatingdriveshaft, with the sensor sensing pressure drop across the coalescermedia.

In the foregoing description, certain terms have been used for brevity,clarity, and understanding. No unnecessary limitations are to beinferred therefrom beyond the requirement of the prior art because suchterms are used for descriptive purposes and are intended to be broadlyconstrued. The different configurations, systems, and method stepsdescribed herein may be used alone or in combination with otherconfigurations, systems and method steps. It is to be expected thatvarious equivalents, alternatives and modifications are possible withinthe scope of the appended claims. Each limitation in the appended claimsis intended to invoke interpretation under 35 U.S.C. §112, sixthparagraph, only if the terms “means for” or “step for” are explicitlyrecited in the respective limitation.

What is claimed is:
 1. A method for regenerating and cleaning an air-oilcoalescing filter of a crankcase ventilation system of an internalcombustion engine generating blowby gas in a crankcase, said coalescingfilter coalescing oil from said blowby gas, said method comprisingregenerating and cleaning said coalescing filter by intermittentrotation thereof, and by applying centrifugal force thereto by saidintermittent rotation thereof, the intermittent rotation controlledaccording to pressure drop across said coalescing filter.
 2. The methodaccording to claim 1 comprising regenerating and cleaning saidcoalescing filter by intermittent rotation driven by a rotary shaft. 3.The method according to claim 2 wherein said rotary shaft is driven bysaid engine.
 4. The method according to claim 1 comprising regeneratingand cleaning said coalescing filter by intermittent rotation driven byan electric motor.
 5. The method according to claim 1 comprisingregenerating and cleaning said coalescing filter by intermittentrotation driven by a hydraulic motor.
 6. The method according to claim 1comprising regenerating and cleaning said coalescing filter byintermittent rotation driven by pressurized engine oil.
 7. The methodaccording to claim 6 wherein said engine has an oil pump pumpinglubricating oil to components of said engine, and comprisingregenerating and cleaning said coalescing filter by intermittentrotation driven by pumped oil from said oil pump.
 8. The methodaccording to claim 1 comprising regenerating and cleaning saidcoalescing filter by intermittent rotation driven by pressurized engineoil driving a pelton turbine.
 9. The method according to claim 1 whereinsaid engine has an oil pump pumping lubricating oil to components ofsaid engine and having a relief valve returning excess oil to a sump toprotect against overpressure, and comprising regenerating and cleaningsaid coalescing filter by intermittent rotation driven by excess oilflow from said relief valve.
 10. The method according to claim 1comprising regenerating and cleaning said coalescing filter byintermittent rotation commanded when to spin and when not to spin. 11.The method according to claim 1 comprising regenerating and cleaningsaid coalescing filter by intermittent rotation at a commanded frequencyhaving a plurality of cycles, each cycle having an off interval duringwhich said coalescing filter is stationary and non-rotated, and an oninterval during which said coalescing filter is rotated.
 12. The methodaccording to claim 11 wherein at least one of a) said commandedfrequency, b) the duty cycle of said commanded frequency between saidoff and on intervals, and c) the speed of rotation during said oninterval, is controlled according to a given parameter.
 13. The methodaccording to claim 11 comprising during said on interval, pulsing therotation of said coalescing filter to provide pulsed rotation thereof,including a plurality of centrifugal force impulses thereto duringrotation during said on interval.
 14. The method according to claim 11comprising during said on interval, pulsing the rotation of saidcoalescing filter to provide a plurality of accelerational bursts duringpulsed rotation thereof.
 15. The method according to claim 1 comprisingregenerating and cleaning said coalescing filter by intermittentrotation while said coalescing filter is mounted to said engine.
 16. Asystem for regenerating and cleaning an air-oil coalescing filter of acrankcase ventilation system of an internal combustion engine generatingblowby gas in a crankcase, said coalescing filter coalescing oil fromsaid blowby gas, said system regenerating and cleaning said coalescingfilter by intermittent rotation thereof, said intermittent rotationcontrolled by a controller according to pressure drop across saidcoalescing filter.
 17. The system according to claim 16 wherein saidintermittent rotation is driven by a source selected from the groupconsisting of: a rotary shaft; a rotary shaft driven by said engine; anelectric motor; a hydraulic motor; pressurized engine oil.
 18. Thesystem according to claim 16 wherein said engine has an oil pump pumpinglubricating oil to components of said engine and having a relief valvereturning excess oil to a sump to protect against overpressure, andwherein said system regenerates and cleans said coalescing filter byintermittent rotation driven by excess oil flow from said relief valve.19. The system according to claim 16 wherein said coalescing filter isregenerated and cleaned by intermittent rotation commanded when to spinand when not to spin and wherein the intermittent rotation is controlledby a controller.
 20. The system according to claim 16 wherein saidcoalescing filter is regenerated and cleaned by intermittent rotation ata commanded frequency having a plurality of cycles, each cycle having anoff interval during which said coalescing filter is stationary andnon-rotated, and an on interval during which said coalescing filter isrotated, and wherein the intermittent rotation is controlled by acontroller.
 21. The system according to claim 20 wherein at least one ofa) said commanded frequency, b) the duty cycle of said commandedfrequency between said off and on intervals, and c) the speed ofrotation during said on interval, is controlled according to a givenparameter.
 22. The system according to claim 20 wherein during said oninterval, said system pulses the rotation of said coalescing filter toprovide pulsed rotation thereof, including a plurality of centrifugalforce impulses during rotation during said on interval.
 23. The systemaccording to claim 20 wherein during said on interval, said systempulses the rotation of said coalescing filter to provide a plurality ofaccelerational bursts during rotation thereof.
 24. The system accordingto claim 16 wherein said coalescing filter is regenerated and cleaned byintermittent rotation while said coalescing filter is mounted to saidengine.